komax Holding
 

Professionals in Advanced Automation

Alpha 355 – fully automatic crimping machine

Introduction

Short setup and changeover times, integrated quality measurements, and top performance are the three main features of the Alpha 355 fully automatic crimping machines.
  • Picture:
  • 1|
  • 2|
  • 3|
  • 4

Key features:

  • Short changeover times
  • Reliable process monitoring
  • High production output
  • Setup of next job while production of current job is underway

Area of application

The Komax Alpha 355 is designed for one and two-sided crimping and seal loading.  It even handles double-crimp connections involving varying lengths and the same wire types without any problem.  
The ultra-precise dual-channel blade system allows for a large range of wire sizes without blade changes.

Fast changeovers

In most machines, changeover times offer the biggest potential for optimization. With options like the manual wire selector and/or the quick-change system for crimping tools, materials and tools can be prepared for the next job while the machine is running.
Jobs can also be recorded and edited with TopWin while the machine is running. The changeover time is displayed, providing an easy method for optimizing the workflow.

Maximum quality control

Crimp-height measurement and fully automatic pull-out force measurement are integrated in the process sequence. Optional material-change detection and the optional barcode scanner help to prevent materials from getting mixed up.
The processes are constantly checked against the specified values during production with functions that monitor crimp force, seals, splices, end of wire supply, and length. Any cables with processing defects are removed and an appropriate number of cables are post-processed automatically to replace them.

User friendly

The drive unit for the blade head is placed underneath, giving the machine a neat and ergonomic layout. All processing stations have safety covers that open vertically for optimum access, and application-specific parts like applicators and contact rolls can be changed without tools. Controls are placed at decentralized positions, allowing the necessary machine functions to be triggered during setup. All setting and adjustment procedures can be controlled from the TopWin graphical user interface in the operator’s choice of over 20 different languages.

mci 712/722 crimp module

Presses with integrated crimp force monitoring and analysis for crimping forces up to 20kN.
  • Just one teach crimp is required.
  • Creep speed (slow motion) and other key functions can be controlled right at the press.
  • Split cycle function
  • Programmable stroke
  • Tool fixture featuring quick-change system
  • The mci 722 crimp press also features programmable crimp height adjustment.

mci 765 seal module

Module with integrated seal monitoring.
  • The most important functions can be operated right at the module.
  • Quick-release locks for all seal-dependent application parts.
  • Existing applications can be used.
  • Automatic setup and SPM seal position monitoring

TopWin

The TopWin graphical user interface is designed for quick and simple data input. With its easy-to-understand structure, users are able to master the machine in no time at all. User tips are presented clearly in graphics. Access rights to all important input parameters can be managed with a permission editor. The optional interface, the WPCS (Wire Processing Communication Standard), allows Komax machines to be networked and easily integrated into existing production processes.
The supplemental TopNet networking software ensures that job processing proceeds in the optimum order.

Technical data

Length range
60mm–65000mm(2.36in.–213ft.)
Optionally from 30mm(1.18in.)
Length accuracy
Repeat accuracy: ±(0.2%+1.0mm (0.04in.))
Stripping lengths
0.1–35mm (0.004–1.38in.)
Stripping lengths with partial pull-off
Beginning of wire35mm ±1mm (1.38in. ±0.04in.)
End of wire35mm ±1mm (1.38in. ±0.04in.)
Conductor cross sections*
0.22mm2–6.0mm2 (AWG24–AWG10)
Optionally from 0.13mm2 (AWG26)
Wire draw-in speed
Maximum of 10m/s (33ft/s)
Noise level
<75dB (without crimp tools)
Electrical connection
3×208–480V 50/60Hz, 5kVA
Pneumatic connection
5–8bar (73–116psi)
Air consumption
9m3/h (318ft3/h)
Weight
1300kg (2866lb) including two crimp and seal modules
*extremely hard, tough wires may not be able to be processed even if they are within the indicated cross section range. In case of doubt, we are happy to produce samples of your wires.

Accessories

The Komax Alpha 355 can be customized with various accessories to meet specific customer needs.
Preliminary processing of wires
  • Variety of wire feed systems
  • Inkjet marking
  • Straightening unit, standard/manual wire selector
Measuring devices
  • Integrated crimp height measurement
  • Integrated pull-out force measurement
  • Fully automatic pull-out force measurement
Wire deposition
  • Basic module, 2m or 4m
  • Extension module, 2m or 4m
Crimping module accessories
  • Quick-change system for tools
  • Terminal feed with paper take-up unit
  • Contact strip chopper (chopper)
  • Process monitoring
  • Crimp force monitoring
  • Seal monitoring
  • Spark tester
  • Splice detection
  • Wire-end detection
Other accessories
  • Automatic guide tube changer
  • Double gripper module
  • Material change detection
  • Barcode scanner
Services
Komax naturally provides optimum support after your purchase as well.
  • Putting the module into operation
  • Production assistance
  • Training for different levels of users
  • Worldwide customer service network with seamless supply of spare parts
 

For more information please contact:

Komax AG, Dierikon
Tel. +41 (0)41 455 04 55
mailto: Komax AG Dierikon
 

Downloads